Friction Stir Extrusion (FSE) of Modular Lunar Solar Array Structures and Sub-Components (FSE)

Lunar infrastructure development presents significant logistical challenges due to payload constraints and reliance on Earth-based manufacturing. This proposal introduces Friction Stir Extrusion (FSE) as an innovative solid-state manufacturing method to enable in situ production of modular structural components and electrical wiring for lunar solar tower arrays and other infrastructure. FSE utilizes a compact, low-power, gravity-insensitive extrusion process that transforms feedstock into high-quality, continuous extrusions of complex geometries without melting the material. Unlike traditional extrusion methods, this approach reduces energy consumption, enhances material properties, and is scalable to produce extrusions of virtually unlimited length. The Phase I effort will focus on designing and fabricating a single-pin FSE system with a ram-rod-style feed mechanism to validate key processing parameters. This will include extruding multiple geometries, performing metallographic and mechanical testing, and delivering samples to NASA for evaluation. Additionally, the study will assess surface finish enhancements via low-friction coatings and establish a roadmap for Phase II, which will expand the process to multi-pin extrusions and continuous feed systems for large-scale lunar applications. Beyond lunar construction, this technology has broad applications in terrestrial aerospace, defense, and industrial manufacturing, offering an energy-efficient alternative to traditional extrusion. The requested funding will demonstrate process feasibility, optimize extrusion parameters, and establish the groundwork for scalable lunar manufacturing, aligning with NASA's TX12.2 H5.01 objectives for modular lunar structures.

In-Space Applications 1) Extrusion of modular subcomponents of lunar tower arrays 2) Extrusion of electric wire on the lunar surface 3) In-space recycling of metallic structures 4) Extrusion of components needed for on-orbit manufacturing Terrestrial Applications 1) Extrusions to replace ring forgings of rocket propellant tanks 2) Use of multi-pin to extrude the entire rocket propellant tank barrels in a single extrusion 1) Extrusion manufacturing companies 2) Small run extrusions of unique shapes or alloys 3) Aircraft extrusions in critical locations where the enhanced microstructure would reduce weight. 4) Ship building, or other industries, where large continuous length extrusions would be beneficial if produced on-site

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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